RKI Instruments 65-2515RK Owner's manual

Brand: RKI Instruments

Model: 65-2515RK

Type: Owner's manual

www.rkiinstruments.com

65-2515RK

Oxygen Detector

Operator’s Manual

Part Number: 71-0137RK

Revision: A

Released: 7/7/20

2 • 65-2515RK Oxygen Detector

WARNING

Read and understand this instruction manual before operating detec-

tor. Improper use of the detector could result in bodily harm or death.

Periodic calibration and maintenance of the detector is essential for

proper operation and correct readings. Please calibrate and maintain

this detector regularly! Frequency of calibration depends upon the

type of use you have and the sensor types. Typical calibration frequen-

cies for most applications are between 3 and 6 months, but can be

required more often or less often based on your usage.

65-2515RK Oxygen Detector • 3

Product Warranty

RKI Instruments, Inc. warrants gas alarm equipment sold by us to be free from defects in

materials, workmanship, and performance for a period of one year from date of shipment from

RKI Instruments, Inc. Any parts found defective within that period will be repaired or

replaced, at our option, free of charge. This warranty does not apply to those items which by

their nature are subject to deterioration or consumption in normal service, and which must be

cleaned, repaired, or replaced on a routine basis. Examples of such items are:

Warranty is voided by abuse including mechanical damage, alteration, rough handling, or

repair procedures not in accordance with the operator’s manual. This warranty indicates the

full extent of our liability, and we are not responsible for removal or replacement costs, local

repair costs, transportation costs, or contingent expenses incurred without our prior approval.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL OTHER WARRANTIES

AND REPRESENTATIONS, EXPRESSED OR IMPLIED, AND ALL OTHER

OBLIGATIONS OR LIABILITIES ON THE PART OF RKI INSTRUMENTS, INC.

INCLUDING BUT NOT LIMITED TO, THE WARRANTY OF MERCHANTABILITY OR

FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL RKI INSTRUMENTS,

INC. BE LIABLE FOR INDIRECT, INCIDENTAL, OR CONSEQUENTIAL LOSS OR

DAMAGE OF ANY KIND CONNECTED WITH THE USE OF ITS PRODUCTS OR

FAILURE OF ITS PRODUCTS TO FUNCTION OR OPERATE PROPERLY.

This warranty covers instruments and parts sold to users by authorized distributors, dealers,

and representatives as appointed by RKI Instruments, Inc.

We do not assume indemnification for any accident or damage caused by the operation of this

gas monitor, and our warranty is limited to the replacement of parts or our complete goods.

a) Absorbent cartridges d) Batteries

b) Pump diaphragms and valves e) Filter elements

c) Fuses

4 • 65-2515RK Oxygen Detector

Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Oxygen Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Junction Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Mounting the Oxygen Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Wiring the Oxygen Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Introducing Incoming Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Verifying/Setting the Fresh Air Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Replacing the Oxygen Plug-in Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Replacing the Oxygen Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Calibration Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Setting the Fresh Air Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Setting the Zero Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Returning to Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

65-2515RK Oxygen Detector • 5

Overview

This manual describes the 65-2515RK oxygen detector (internal amplifier type). This manual

also describes how to install, start up, maintain, and calibrate the detector when used with a

gas monitoring controller. A parts list at the end of this manual lists replacement parts and

accessories for the oxygen detector.

Specifications

Table 1 lists specifications for the 65-2515RK oxygen detector.

NOTE: The following symbol on the detector label is a caution to the user to refer to this

documentation for installation and operation instructions:

WARNING: When using the 65-2515RK, you must follow the instructions and warnings in

this manual to assure proper and safe operation of the 65-2515RK and to

minimize the risk of personal injury. Be sure to maintain and periodically

calibrate the 65-2515RK as described in this manual.

Table 1: 65-2515RK Specifications

Target Gas Oxygen

Sampling Method Diffusion

Detection Range 0 - 25.0% oxygen

Accuracy ± 0.5% O

Oxygen Detector Signal Output 0 mV at 0% volume oxygen nominal

18 mV at 25% oxygen nominal

Response Time 90% in 30 seconds

Area Classification Explosionproof for Class I, Groups B, C, and D

Temperature Code T6

Installation Category Installation Category 1. Signal level, special equipment or

parts of equipment, telecommunication, electronic, etc.,

with smaller transient overvoltages than Installation

Category (Overvoltage Category) II (ref. IEC 664).

Operating Temperature -20° C to 45° C

6 • 65-2515RK Oxygen Detector

Description

This section describes the components of the 65-2515RK. It consists of the oxygen detector

and the junction box

Oxygen Detector

The oxygen detector consists of the detector housing and the plug-in sensor.

Figure 1: Oxygen Detector Component Location

Detector Housing

The detector housing protects the sensing components within the housing. Use the mounting

threads at the top of the housing to screw the oxygen detector into the bottom conduit hub of

the junction box. Use the removable cap near the bottom of the housing to access the sensor

for maintenance or replacement. The cap protects the sensor from damage and includes a

flame arrestor which contains any sparks that may occur within the detector housing. A cap

gasket seals the interface between the housing body and cap. The flame arrestor guard protects

the flame arrestor from impact damage and is permanently bonded to the cap.

Two color coded wires extend from the top of the detector housing. Use these wires to connect

the oxygen detector to a controller via the terminal block in the junction box. The detector

housing includes two sockets installed on a circuit board. These sockets accept the plug-in

sensor’s two pins to secure the sensor within the detector housing. The circuit board with the

sockets conditions the sensor’s signal before it exits the detector housing via the two color

coded wires.

Plug-In Sensor

The plug-in sensor plugs into a circuit board in the detector housing with two pins and is

retained by the cap. Through a series of chemical and electrical reactions, the sensor produces

an electrical output that is proportional to the detection range of the oxygen detector.

Detector

Housing Body

Cap Gasket

Detector Housing

Cap

Flame Arrestor

Guard

Oxygen Sensor

65-2515RK Oxygen Detector • 7

Junction Box

The junction box allows you to install the oxygen detector at a mounting site that is remote

from a controller and it protects the detector wiring connections. Two conduit hubs allow you

to mount the oxygen detector to the junction box and route the wiring from the detector to a

controller. Three spacers installed on the back of the junction box control the distance of the

junction box from a mounting surface and ensure that there is enough room to install a

calibration cup on the detector during calibration.

A terminal block within the junction box facilitates the wiring process. A cover on the front

of the junction box allows access to the interior of the junction box.

Installation

This section describes procedures to mount the oxygen detector in the monitoring

environment and wire the detector to a controller.

Mounting the Oxygen Detector

1. Select a mounting site that is representative of the monitoring environment. Consider the

following when you select the mounting site.

• Select a site where the detector is not likely to be bumped or disturbed. Make sure

there is sufficient room to perform start-up, maintenance, and calibration procedures.

• Select a site that is at normal breathing level.

8 • 65-2515RK Oxygen Detector

Figure 2: 65-2515RK Outline & Mounting Dimensions

NOTE: The oxygen detector in the 65-2515RK is normally provided with an Adalet

XIHSCFC3 junction box rated explosion proof for Class I, Groups B, C, and D. This

combination is shown in Figure 2 above. Any junction box with an internal volume

less than or equal to 69 cubic inches and rated explosion proof for Class I, Groups B,

C, and D may be used for this detector.

2. At the mounting site you select, hang or mount the junction box with the detector facing

down (see Figure 2).

Rubber Spacers,3X

.38

.75

3.2 Max

3/4 NPT Conduit

Hub

11/2-20Thread for

Calibration Cup

3.62

8.45 Max

2.7

65-2515RK Oxygen Detector • 9

Wiring the Oxygen Detector to a Controller

WARNING: If the controller’s construction is not explosion-proof, the controller must be

installed in an ordinary location. Do non install a non-explosion-proof

controller in a classified location. Turn off the controller.

3. Turn off or unplug power to the controller.

4. Remove the junction box cover.

5. Guide a two-conductor, shielded cable or two wires in conduit through the unused conduit

hub of the junction box.

WARNING: To maintain the explosion proof classification of the oxygen detector/junction

box combination, a conduit seal must be used within 2 inches (environment

with acetic acid) or 18 inches (environment without acetic acid) of the detector

junction box conduit hub used for wiring to the amplifier. Adhere to your local

electrical code when installing the conduit seal.

6. Connect the wires to the terminals opposite the detector leads using the terminal strip in

the junction box.

CAUTION: If using shielded cable, leave the drain wire insulated and disconnected at the

detector. You will connect the opposite end of the cable’s drain wire at the

controller.

7. Reinstall the junction box cover to the junction box.

8. Route the cable or wires leading from the oxygen detector through one of the conduit hubs

at the controller housing.

CAUTION: Do not route power and detector wiring through the same conduit hub. The

power cable may disrupt the transmission of the detector signal to the controller.

9. Connect the wires to the applicable controller terminal strip as shown in Figure 3 below.

See the controller operator’s manual and the controller’s detector head specification sheet

for wiring information specific to a controller.

10 • 65-2515RK Oxygen Detector

Figure 3: Wiring the Oxygen Detector to a Controller

10. If using shielded cable, connect the cable’s drain wire to an available chassis ground at the

controller. RKI controllers typically have a ground stud that is a convenient grounding

location.

Install conduitsealwithin 18

inches (for environments

without acetic acid) or2

inches (for environments with

acetic acid)

Green (-)

White(+)

Cable

Shield

Terminal Strip

White

Green

Oxygen Detector

Controller Housing

(installed inordinary location if

device is non-explosion-proof)

Controller

Oxygen Detector

Terminals

65-2515RK Oxygen Detector • 11

Start Up

This section describes procedures to start up the oxygen detector and place the detector into

normal operation.

Introducing Incoming Power

1. Complete the installation procedures described earlier in this manual.

2. Verify that the power wiring to the controller is correct and secure. Refer to the controller

operator’s manual.

3. Turn on or plug in the incoming power to the controller, then turn on the controller.

4. Verify that the controller is on and operating properly. Refer to the controller operator’s

manual.

CAUTION: Allow the detector to warm up for 5 minutes before you continue with the next

section, “Verifying/Setting the Fresh Air Reading”.

Verifying/Setting the Fresh Air Reading

WARNING: Do not remove the detector housing cap or junction box cover while the

circuits are energized unless the area is determined to be non-hazardous. Keep

the detector housing cap and junction box cover tightly closed during

operation.

NOTE: If you can verify that the detector is in a fresh air environment (environment known to

be of normal oxygen content and free of toxic and combustible gases), it is not

necessary to apply zero air when verifying or setting the fresh air reading.

The procedure below describes applying zero air using a calibration kit that includes a

calibration cup, calibration gas, sample tubing, and a fixed flow regulator with an on/off knob.

RKI Instruments, Inc. recommends using a 0.5 LPM (liters per minute) fixed flow regulator.

1. Screw the calibration cup onto the bottom of the oxygen detector.

2. Screw the regulator into the zero air calibration cylinder.

3. Use the sample tubing to connect the regulator to the calibration cup.

4. Turn the regulator’s on/off knob counterclockwise to open it. Gas will begin to flow.

5. Allow the gas to flow for two minutes.

12 • 65-2515RK Oxygen Detector

6. Verify a reading of 20.9% oxygen at the controller.

If the display reading is 20.9% oxygen, the oxygen detector is in normal operation and

start up is complete. Proceed to step 7 to disassemble the calibration kit.

If the display reading is not 20.9% oxygen, set the fresh air reading according to the

controller’s operator’s manual.

7. Turn the regulator’s on/off knob clockwise to close it.

8. Unscrew the regulator from the zero air calibration cylinder. For convenience, leave the

sample tubing connected to the regulator and the calibration cup.

9. Unscrew the regulator from the cylinder and remove the calibration cup from the detector.

10. Store the components of the calibration kit in a safe and convenient place.

Maintenance

This section describes maintenance procedures. It includes preventive maintenance,

troubleshooting, and component replacement procedures.

Preventive Maintenance

This section describes a preventive maintenance schedule to ensure the optimum performance

of the oxygen detector. It includes daily and quarterly procedures.

Daily

Verify a display reading of 20.9% oxygen at the controller. Investigate significant changes in

the reading.

Quarterly

Calibrate the detector as described in “Calibration” on page 15.

65-2515RK Oxygen Detector • 13

Troubleshooting

The troubleshooting guide describes symptoms, probable causes, and recommended action for

problems you may encounter with the oxygen detector.

NOTE: This troubleshooting guide describes detector problems only. See the controller

operator’s manual for problems you may encounter with the controller.

Replacing the Oxygen Plug-in Sensor

1. Turn off the controller.

2. Turn off or unplug incoming power to the controller.

3. Unscrew the detector housing cap from the detector housing.

4. Unplug and remove the oxygen sensor.

5. Carefully plug the replacement sensor into the socket pattern that is located in the top

section of the detector housing.

NOTE: Match the sensor’s male pins with the two female sockets as you plug the sensor into

the sockets.

Table 2: Troubleshooting the Oxygen Detector

Condition Symptom(s) Probable Causes Recommended Action

Fail

Condition

• Controller indicates

a fail condition.

• The detector wiring is

disconnected or

misconnected.

• The plug-in oxygen

sensor is not properly

installed.

• The detector is

malfunctioning.

1. Verify that the detector wiring is

correct and secure.

2. Confirm that the plug-in oxygen

sensor inside the detector housing is

installed properly.

3. Calibrate the detector.

4. If the fail condition continues,

replace the plug-in oxygen sensor.

5. If the fail condition continues,

contact RKI for further instruction.

Slow or No

Response/

Difficult or

Unable to

Calibrate

• Unable to accurately

set the fresh air or

zero reading during

calibration.

• Detector requires

frequent calibration.

Note: Under

“normal”

circumstances, the

detector requires

calibration once every

three months.

Some applications may

require a more frequent

calibration schedule.

• The calibration

cylinder is low, out-

dated, or defective.

• The plug-in sensor is

malfunctioning.

1. Verify that the calibration cylinder

contains an adequate supply of a

fresh test sample.

2. If the calibration/response difficulties

continue, replace the plug-in sensor.

3. If the calibration/response difficulties

continue, contact RKI for further

instruction.

14 • 65-2515RK Oxygen Detector

6. Screw the detector housing cap onto the detector housing.

7. Turn on or plug in incoming power to the controller.

8. Turn on the controller.

CAUTION: Allow the replacement sensor to warm up for 5 minutes before you continue with

the next step.

9. Calibrate the replacement sensor as described in “Calibration” on page 15.

Replacing the Oxygen Detector

NOTE: In most cases, it is only necessary to replace the plug-in oxygen sensor.

1. Turn off the controller.

2. Turn off or unplug incoming power to the controller.

3. Remove the junction box cover.

4. Disconnect the detector leads from the terminal block inside the junction box. Note the

position of the color-coded leads as you remove them.

5. Unscrew the detector from the junction box.

6. Guide the detector leads of the replacement detector through the bottom conduit hub of the

junction box, then screw the mounting threads of the detector into the conduit hub.

7. Wire the detector leads to the terminal block in the same position as the leads you removed

in step 4.

8. Reinstall the junction box cover.

9. Turn on or plug in incoming power to the controller.

10. Turn on the controller.

CAUTION: Allow the replacement detector to warm up for 5 minutes before you continue

with the next step.

11. Calibrate the replacement detector as described in “Calibration” on page 15.

65-2515RK Oxygen Detector • 15

Calibration Frequency

Although there is no particular calibration frequency that is correct for all applications, a

calibration frequency of every 3 to 6 months is adequate for most applications. Unless

experience in a particular application dictates otherwise, RKI Instruments, Inc. recommends a

calibration frequency of every 3 months (quarterly).

If an application is not very demanding, for example detection in a clean, temperature

controlled environment, and calibration adjustments are minimal at calibration, then a

calibration frequency of every 6 months is adequate.

If an application is very demanding, for example if the environment is not well controlled,

then more frequent calibration than every 3 months may be necessary.

Calibration

This section describes how to calibrate the oxygen detector. It includes procedures to prepare

for calibration, set the fresh air reading, set the zero reading, and return to normal operation. It

describes calibration using a calibration kit that includes a calibration cup, calibration gas,

sample tubing, and a fixed flow regulator with an on/off knob. RKI Instruments, Inc.

recommends using a 0.5 LPM (liters per minute) fixed flow regulator.

WARNING: The controller is not an active gas monitoring device during the calibration

procedure.

Preparing for Calibration

NOTE: Calibrating the oxygen transmitter may cause alarms. Be sure to put the controller

into its calibration program or disable external alarms before calibrating.

1. Screw the calibration cup onto the bottom of the oxygen detector.

2. Screw the regulator into the zero air calibration cylinder.

3. Use the sample tubing to connect the regulator to the calibration cup.

NOTE: If you can verify that the oxygen detector is in a fresh air environment, you do not

need to apply zero air to the detector before adjusting the zero reading.

4. Put the controller into its calibration program.

Setting the Fresh Air Reading

1. Follow the directions in the controller operator’s manual for setting the fresh air reading.

2. When the instructions call for applying zero air to the detector, turn the regulator’s on/off

knob counterclockwise to open it. Zero air will begin to flow.

3. Allow the gas to flow for two minutes.

16 • 65-2515RK Oxygen Detector

4. Set the fresh air reading according to the controller operator’s manual.

5. Turn the regulator’s on/off knob clockwise to close it.

6. Unscrew the regulator from the zero air calibration cylinder. Leave the sample tubing

connected to the regulator and the calibration cup.

Setting the Zero Reading

1. Screw the regulator into the calibration gas cylinder, normally 100% nitrogen.

2. Follow the instructions in the controller’s operator’s manual for setting the oxygen zero

reading.

3. When the instructions call for exposing the detector to gas, normally 100% nitrogen, turn

the regulator’s on/off knob counterclockwise to open it. Gas will begin to flow.

4. Allow gas to flow to the detector for two minutes.

5. Set the zero reading according to the controller operator’s manual.

6. Turn the regulator’s on/off knob clockwise to close it.

7. Unscrew the regulator from the cylinder.

8. Remove the calibration cup from the detector. For convenience, leave the calibration cup

and regulator connected by the sample tubing.

Returning to Normal Operation

1. Allow about 45 seconds for the oxygen reading to increase above the decreasing alarm

point and return the controller to normal operation.

NOTE: If you do not allow the oxygen reading to increase above the decreasing alarm point,

then unwanted alarms may occur.

2. Verify that the controller display reading increases and stabilizes at 20.9% oxygen.

3. Store the components of the calibration kit in a safe and convenient place.

65-2515RK Oxygen Detector • 17

Parts List

Table 3 lists replacement parts and accessories for the oxygen detector.

Table 3: Parts List

Part Number Description

06-1248RK Sample tubing (3/16 in. x 5/16 in.; specify length when ordering)

18-0400RK-01 Junction box with spacers

65-1025RK Oxygen replacement sensor, plug-in

65-2514RK Oxygen replacement detector assembly (includes plug-in sensor), CSA

classified (does not include junction box)

65-2515RK Oxygen detector/junction box, CSA classified

71-0137RK 65-2515RK Oxygen Detector Operator’s Manual (this document)

81-0076RK-01 Zero air calibration cylinder, 34 liter steel

81-0078RK Calibration cylinder, 100% nitrogen, 17 liter

81-0078RK-01 Calibration cylinder, 100% nitrogen, 34 liter steel

81-1050RK Regulator with gauge and knob, 0.5 LPM, for 17- and 34-liter steel

calibration cylinders (cylinders with external threads)

81-1117RK Calibration cup

81-F301RK-LV Calibration kit (34 liter)

RKI Instruments 65-2515RK Owner's manual

RKI Instruments 65-2515RK Owner's manual

RKI Instruments 65-2515RK Owner's manual

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